How Omron Helped a Company Safeguard Its Purlin Stacker While Maximizing Uptime


June 21, 2021

Large and potentially hazardous machinery is a mainstay of many manufacturing companies, and safeguarding is critical in preventing serious accidents. While it’s never acceptable to provide less protection for the sake of boosting productivity, many manufacturers are seeking to determine which solutions offer full protection while maximizing uptime.

Downtime can be exceedingly expensive, particularly when it involves large machinery. In a recent safety-related project, Omron helped a metal forming company properly safeguard its purlin stacker without the need for a long and costly shutdown. As it turned out, the Omron F3SG-SR Series safety light curtain addressed this need perfectly.

Hazards of a large, production-critical machine

A purlin stacker handles, transports, positions, and stacks extremely large, heavy steel purlins off the end of a steel forming line so that the product can be offloaded by a forklift operator. Hazards of this type of machine include multiple heavy-duty, high-load, sprocket-driven chain conveyors, high-load scissor lifts, high-force positioning actuators, conveyance, and more.

Simply safeguarding the machine is in itself quite a challenge, but this challenge is compounded by the fact that every second of installation- or maintenance-related downtime corresponds to fewer purlins produced and less revenue to plant operations. Multiple safety devices of various types guard the machine and feed into a safety controller that controls the entire process.

Keeping production moving with flexible safety technology

The metal forming company employed a safety zoning strategy in which specific safety devices would shut down their associated areas while production would continue in all other areas that were deemed safe. Light curtains made the most sense for safeguarding each area, but it was difficult to find any that were flexible enough to meet the zones’ varying requirements.

Fortunately, the Omron F3SG-SR safety light curtain is designed to maximize flexibility and minimize installation time. The available range (30m protection range at 25mm resolution) provided the added power to cover the requisite distance and reduce customer maintenance procedures by more effectively operating through dust and dirt buildup.

The metal forming company also found value in the F3SG-SR’s Intelligent Tap module that offers diagnostic data for system maintenance and troubleshooting, including insight into percent excess gain for each beam to guide predictive (as opposed to preventive) maintenance.


Related Articles

Changing Scene

  • Tri-Mach Announces the Purchase of an Additional 45,000 sq ft. Facility

    Tri-Mach Announces the Purchase of an Additional 45,000 sq ft. Facility

    Recently, Tri-Mach Inc. was thrilled to announce the addition of a new 45,000 sq ft. facility. Located at 285 Union St., Elmira, ON, this facility expands Tri-Mach’s capabilities, allowing them to better serve the growing needs of their customers. Positioning for growth, this additional facility will allow Tri-Mach to continue taking on large-scale projects, enhance product performance testing, and provide equipment storage for their customers. Read More…

  • HELUKABEL Group Builds New Facility for Automation Cable Solutions

    HELUKABEL Group Builds New Facility for Automation Cable Solutions

    The HELUKABEL Group recently announced it is going to build a new facility in Haan, Germany that will house its robotic dress pack and drag chain system subsidiaries under one roof. The new building will also serve as the headquarters of HELUKABEL’s Rhine-Ruhr sales branch, and is planned to be completed by 2025. Robotec Systems’ core business is robotic dress pack solutions and has been a HELUKABEL subsidiary since 2012 operating out of Duisburg, a suburb of Duesseldorf in northwest Germany. Read More…

Sponsored Content
Fire Protection for Lithium-ion Battery Energy Storage Systems

Lithium-ion storage facilities contain high-energy batteries combined with highly flammable electrolytes. In addition, they are prone to quick ignition and explosion in a worst-case scenario. Such fires can have a significant financial impact on organizations. Rapid detection of electrolyte gas particles and extinguishing are the key to a successful fire protection concept. Since December 2019, Siemens has been offering a VdS-certified fire protection concept for stationary Li-ion battery storage systems.

Click HERE to learn more.

For a Multiplied Value Unified


During the last few years, the Excelpro Group has welcomed AIA Automation, Envitech Automation and Conrad Lavoie Electrical, all of which have become ‘Member of the Excelpro Group’.

It was with great excitement that in November of 2022, Excelpro announced that these three companies officially became Excelpro. This decision is part of a strategy to enhance the Excelpro Group’s brand in its market.

These companies already collaborate on various client projects. This merger brings together the complementary strengths of the employees and ensures a global synergy of the activities throughout the Group.

Read More

Service Wire Co. Announces New Titles for Key Executives

Bruce Kesler and Mark Gatewood have been given new titles and responsibilities for Service Wire Co.

Bruce Kesler has assumed the role of Senior Director – Business Development. Bruce will be responsible for Service Wire’s largest strategic accounts and our growing Strategic Accounts Team.

Mark Gatewood has been promoted to the role of Vice President – Sales & Marketing. In this role, Gatewood will lead the efforts of Service Wire Company’s entire sales and marketing organization in all market verticals.

Read More

Modern Niagara Partners with Global Sustainability Platform Worldfavor

Worldfavor is a global sustainability platform, digitizing and automating the collection, calculation, aggregation and visualization for analysis and reporting of ESG data. Now, Worldfavor is proud to welcome Modern Niagara as a new customer. Modern Niagara is the first Canadian construction company to partner with Worldfavor.

“Worldfavor was founded to be the best platform for sharing, accessing and gaining insights from corporate ESG information. Worldfavor’s mission is to make sustainability mainstream and with that we offer solutions to accelerate sustainability through the value chain. Modern Niagara is the first Canadian construction company to partner with Worldfavor. 

Read More

JMP Parent Company, CONVERGIX Acquires AGR Automation, Expanding Global Reach

Convergix Automation Solutions has completed the acquisition of AGR Automation (“AGR”), a UK-based provider of custom, high-performance automation design and systems integration primarily to the life sciences industry.

Following Convergix’s acquisitions of JMP Solutions in August 2021 and Classic Design in February 2022, AGR marks the third investment in Crestview’s strategy to build Convergix into a diversified automation solutions provider targeting the global $500+ billion market, with a particular focus on the $70 billion global systems integration and connectivity segments. Financial terms of the transaction were not disclosed.

Read More

Latest Articles